Operator s Manual QS-12W QS-15W QS-20W ANSI / CSA with Maintenance Information First Edition Second Printing Part No. 133494
First Edition Second Printing Important Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries. Contents Page Introduction... 1 Symbol and Hazard Pictorials Definitions... 3 General Safety... 5 Personal Safety... 9 Work Area Safety... 10 Legend... 17 Controls... 18 Inspections... 21 Operating Instructions... 32 Transport and Lifting Instructions... 38 Maintenance... 41 Specifications... 43 Contact us: Internet: http://www.genielift.com e-mail: techpub@genieind.com Copyright 2009 by Genie Industries First Edition: Second Printing, November 2009 "Genie" is a registered trademark of Genie Industries in the U.S.A. and many other countries. These machines comply with ANSI/SIA 92.6 CAN/CSA B354.2 Printed on recycled paper Printed in U.S.A. QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Introduction Owners, Users and Operators: Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: 1 Comply with employer, job site and governmental rules. 2 Read, understand and follow the instructions in this and other manuals supplied with this machine. 3 Use good safe work practices in a common sense way. 4 Only have trained/certified operators, directed by informed and knowledgeable supervision, running the machine. If there is anything in this manual that is not clear or which you believe should be added, please contact us. Internet: www.genielift.com E-mail: techpub@genieind.com Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. Know and understand the safety rules before going on to the next section. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended. You read, understand and obey the manufacturer's instructions and safety rules safety and operator's manuals and machine decals. You read, understand and obey employer's safety rules and work site regulations. You read, understand and obey all applicable governmental regulations. You are properly trained to safely operate the machine. Part No. 133494 QS-12W QS-15W QS-20W 1
First Edition Second Printing Introduction Hazard Classification Genie uses symbols, color coding and signal words to identify the following: Red Orange Yellow Blue Safety alert symbol used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates a property damage message. Intended Use This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site. Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material. 2 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Symbol and Hazard Pictorials Definitions Read the operator s manual Read the service manual Crush hazard No smoking Collision hazard Collision hazard Tip-over hazard Tip-over hazard Use a piece of cardboard or paper to search for leaks Electrocution hazard Electrocution hazard Explosion hazard Fire hazard Burn hazard Skin injection hazard Transport diagram Tiedown Keep away from moving parts Move machine to level ground Batteries used as counterweights Maintain required clearance Only trained maintenance personnel should access compartments Chock the wheels Release brakes Grounded AC 3-wire only Part No. 133494 QS-12W QS-15W QS-20W 3
First Edition Second Printing Symbol and Hazard Pictorials Definitions Replace damaged wires and cords Wheel load Side force Lanyard attachment point Voltage rating for power to platform Pressure rating for air line to platform Wind speed Maximum capacity including occupant + + 22 kg Maximum capacity including occupant, tools and tray + 4 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing General Safety Safety signs and locations Decals with words DANGER 133014 result in death or serious injury. Improper Use Hazard The operator is responsible for safe machine operation. This includes: 1Avoid hazardous situations. 2Always perform a pre-operation inspection. 3Always perform function tests prior to use. 4Inspect the work place. 5Only use the machine as it was intended. Do not operate unless: You read, understand and obey: - manufacturer s instructions and safety rules safety and operator's manuals and decals - employer s safety rules - applicable governmental regulations You are properly trained to safely operate this machine. Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart. Maintain required clearance. Line voltagerequired clearance 300V to 50KV10 ft3.05 m 50KV to 200KV15 ft4.60 m 200KV to 350KV20 ft6.10 m 350KV to 500KV25 ft7.62 m 500KV to 750KV35 ft10.67 m 750KV to 1000KV45 ft13.72 m Explosion Hazards Do not operate machine or charge battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present. 133014 A Tip-over Hazards Do not exceed rated load capacity. Maximum occupancy: 1 person. Do not raise platform when wind speeds may exceed 28 mph / 12.5 m/s. Do not operate machine in strong or gusty winds. Do not increase surface area of platform or load. Increasing area exposed to wind will decrease machine stability. Do not drive machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the platform raised. Use extreme care and slow speeds while driving the machine in stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs. Do not place or attach overhanging loads to any part of this machine. Do not push off or pull toward any object outside of the platform. Do not alter or disable machine components that in any way affect safety and stability. Do not place ladders or scaffolds in platform or against any part of this machine. Do not drive machine on a slope that exceeds the maximum slope or slide slope rating of the machine. Do not use machine on a moving or mobile surface or vehicle. Be sure all tires are in good condition, castle nuts are properly tightened and cotter pins are properly installed. Do not depend on tilt alarm as a level indicator. Tilt alarm sounds only when the machine is on a slope. If tilt alarm sounds, lower the platform. Move machine to a firm, level surface. Use extreme caution to lower platform. Do not alter or disable limit switches. Crushing Hazards Use common sense and planning when operating machine with controller from ground. Maintain safe distances between operator, machine and fixed objects. Fall Hazards The guard rail system provides fall protection. If occupants of the platform are required to wear personal fall protection equipment (PFPE) due to job site or employer rules, PFPE equipment and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements. Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times. Do not climb down from the platform when raised. Lower platform mid-rail bar or close platform gate before operating. Keep platform floor clear of debris. Collision Hazards Be aware of limited sight distance and blind spots when driving or operating. Check work area for overhead obstructions or other possible hazards. Be aware of crushing hazard when grasping platform guard rail. Do not lower platform unless area below is clear of personnel and obstructions. Be aware of extended platform position when moving machine. No stunt driving or horseplay while operating a machine. Damaged Machine Hazards Do not use a damaged or malfunctioning machine. Be sure all maintenance has been performed as specified in the appropriate operator's and service manuals. Be sure all decals are in place and legible. Be sure operator s, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. 44736 31508 DANGER Part No. 133494 QS-12W QS-15W QS-20W 5
28175 H 133451 A First Edition Second Printing General Safety Safety signs and locations Decals with words 72832 DANGER 31071 WARNING 109519 68 kg Do not overload Tip-over Hazard platform. Overloading the platform Weight in adjustable will cause the machine to work station is part of top-over.machine tip-over total platform load. will cause death or Maximum Adjustable serious injury. Work Station Tray Capacity: 150 lbs / 68 kg 109519 B 28175 WARNING Compartment access is restricted. Contact with components under any cover may result in serious injury. Only trained maintenance personnel should access compartments. Access by operator is only advised when performing Pre-operation Inspection. All compartments must remain closed and secured during operation. 133013 DANGER 82975 31788 DANGER 97712 DANGER INSTRUCTIONS 133451 Tip-over Hazard 45lbs/20kg Do not overload platform. Overloading the platform Weight in bike rack is part of will cause the machine to total platform load. tip-over.machine tip-over Each bike rack maximum will cause death or serious capacity: injury. 45 lbs / 20 kg. DANGER 72159 133092 6 QS-12W QS-15W QS-20W Part No. 133494
82495 B 82481 B 82487 C 114338 A 82473 C 0 to 50KV 3.05 m 50KV to 200KV 4.60 m 200KV to 350KV 6.10 m 350KV to 500KV 7.62 m 500KV to 750KV 10.67 m 750KV to 1000KV 13.72 m 133015 A First Edition Second Printing General Safety Safety signs and locations Decals with symbols 133147 82487 114338 1 2 82614 82473 82614 B 133015 82481 97899 82495 133146 Part No. 133494 QS-12W QS-15W QS-20W 7
114334 A 82966 B 97834 B GR-12 GR-15 97871 B GR-12 GR-15 97872 B GR-20 82487 C First Edition Second Printing General Safety Safety signs and locations Decals with symbols QS-12 & QS-15 97834 227 kg 159 kg 68 kg 0 m/sec 82966 445N or 159 kg 91 kg 68 kg 68 kg 227 kg 68 kg 97835 B GR-20 159 kg QS-20 97835 QS-12 & QS-15 97871 20 kg 20 kg or 227 kg 20 kg 20 kg QS-20 97872 159 kg 82487 114334 133498 8 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Personal Safety Fall Protection Personal fall protection equipment (PFPE) is not required when operating this machine. If PFPE is required by job site or employer rules, the following shall apply: All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer s instructions. Part No. 133494 QS-12W QS-15W QS-20W 9
First Edition Second Printing Work Area Safety Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart. Tip-over Hazards Occupants, equipment and materials must not exceed the maximum platform capacity. Weight in trays and in each bike rack is part of the total platform load. Maximum capacity - QS-12W Platform capacity 500 lbs 227 kg Work tray 150 lbs 68 kg Parcel tray 150 lbs 68 kg Bike rack (option) (each) 45 lbs 20 kg Maximum occupants 1 Maximum capacity - QS-15W Platform capacity 500 lbs 227 kg Line Voltage Required Clearance 0 to 50KV 10 ft 3.05 m 50KV to 200KV 15 ft 4.60 m 200KV to 350KV 20 ft 6.10 m 350KV to 500KV 25 ft 7.62 m 500KV to 750KV 35 ft 10.67 m 750KV to 1000KV 45 ft 13.72 m Allow for platform movement, electrical line sway or sag and beware of strong or gusty winds. Work tray 150 lbs 68 kg Parcel tray 150 lbs 68 kg Bike rack (option) (each) 45 lbs 20 kg Maximum occupants 1 Maximum capacity - QS-20W Platform capacity 350 lbs 159 kg Work tray 150 lbs 68 kg Bike rack (option) (each) 45 lbs 20 kg Maximum occupants 1 Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off. Do not operate the machine during lightning or storms. Do not use the machine as a ground for welding. 10 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Work Area Safety Do not raise the platform unless the machine is on a firm, level surface. Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds inside the battery charger tray only when the machine is on a severe slope. If the tilt alarm sounds: Lower the platform. Move the machine to a firm, level surface. If the tilt alarm sounds when the platform is raised, use extreme caution to lower the platform. Do not drive over 0.5 mph / 0.8 km/h with the platform raised. Do not raise the mast when wind speeds may exceed 28 mph / 12.5 m/s. If wind speeds exceed 28 mph / 12.5 m/s when the platform is raised, lower the platform and do not continue to operate the machine. Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the platform raised. Do not use the machine as a crane. Do not push the machine or other objects with the platform. Do not contact adjacent structures with the platform. Do not tie the platform to adjacent structures. Do not place loads outside of the platform. Bike racks and parcel trays are considered part of the platform. Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls. Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability. Use extreme care and slow speeds while driving the machine in a stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs. Part No. 133494 QS-12W QS-15W QS-20W 11
First Edition Second Printing Work Area Safety Do not push off or pull toward any object outside of the platform. Maximum allowable side force ANSI & CSA 100 lbs 445 N Do not alter or disable the limit switches. Do not alter or disable machine components that in any way affect safety and stability. Do not replace items critical to machine stability with items of different weight or specification. Do not use batteries that weigh less than the original equipment. Batteries are used as counterweight and are critical to machine stability. Each battery must weigh 62 pounds / 28 kg. Do not modify or alter an aerial work platform without prior written permission from the manufacturer. Mounting attachments for holding tools or other materials onto the platform, toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load. Crushing Hazard Keep hands and limbs out of mast. Do not place or attach fixed or overhanging loads to any part of this machine. Do not place ladders or scaffolds in the platform or against any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by the person in the platform. Do not use the machine on a moving or mobile surface or vehicle. Be sure all tires are in good condition, castle nuts are properly tightened and cotter pins are properly installed. Do not work under the platform or mast without the battery cover raised. Use common sense and planning when operating the machine with the controller from the ground. Maintain safe distances between the operator, the machine and fixed objects. Be sure loads on bike racks and in parcel trays are securely positioned and balanced. Use care when transferring loads to and from parcel trays and to and from bike racks. 12 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Work Area Safety Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the slope and side slope rating of the machine. Slope rating applies to machines in the stowed position only. Maximum slope rating, stowed position 30% (17 ) Maximum side slope rating, stowed position 30% (17 ) Note: Slope rating is subject to ground conditions and adequate traction. Fall Hazards The guard rail system provides fall protection. If the occupant of the platform is required to wear personal fall protection equipment (PFPE) due to job site or employer rules, PFPE and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements. Use approved lanyard attachment point provided. Keep the platform floor clear of debris. Lower the platform mid-rail bar or close the entry gate before operating. Do not sit, stand or climb on the platform guard rails or work trays. Maintain a firm footing on the platform floor at all times. Do not climb down from the platform when raised. Do not enter or exit the platform unless the machine is in the stowed position. Lower the platform mid-rail bar or close the platform entry gate before operating. Collision Hazards Be aware of limited sight distance and blind spots when driving or operating. Be aware of the extended platform position when moving the machine. The machine must be on a level surface or secured before releasing the brakes. Part No. 133494 QS-12W QS-15W QS-20W 13
First Edition Second Printing Work Area Safety Check the work area for overhead obstructions or other possible hazards. Be aware of crushing hazards when grasping the platform guard rail. Operators must comply with employer, job site and governmental rules regarding use of personal protective equipment. Do not lower the platform unless the area below is clear of personnel and obstructions. Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin. Improper contact with components under any cover will cause serious injury. Only trained maintenance personnel should access compartments. Access by the operator is only advised when performing a pre-operation inspection. All compartments must remain closed and secured during operation. Explosion and Fire Hazards Do not operate the machine or charge the battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present. Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision. Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision. No stunt driving or horseplay while operating a machine. 14 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Work Area Safety Damaged Machine Hazards Do not use a damaged or malfunctioning machine. Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine. Be sure all maintenance has been performed as specified in this manual and the appropriate service manual. Be sure all decals are in place and legible. Be sure the operator s, safety, and responsibilities manuals are complete, legible and in the storage container located on the platform. Component Damage Hazards Do not use any battery charger greater than 24V to charge the batteries. Do not use the machine as a ground for welding. Part No. 133494 QS-12W QS-15W QS-20W 15
First Edition Second Printing Work Area Safety Battery Safety Burn Hazards Explosion Hazards Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Do not expose the batteries or the charger to water or rain during charging. Keep sparks, flames and lighted tobacco away from batteries. Batteries emit an explosive gas. The battery tray should remain open during the entire charging cycle. Do not contact the battery terminals or the cable clamps with tools that may cause sparks. Component Damage Hazard Do not use any battery charger greater than 24V to charge the batteries. Electrocution/Burn Hazards Connect the battery charger to a grounded, AC 3-wire electrical outlet only. Inspect daily for damaged cords, cables and wires. Replace damaged items before operating. Avoid electrical shock/burns from contact with battery terminals. Remove all rings, watches and other jewelry. Tip-over Hazard Do not use batteries that weigh less than the original equipment. Batteries are used as counterweight and are critical to machine stability. Each battery must weigh 62 pounds / 28 kg. Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries. Lockout After Each Use 1 Select a safe parking location firm level surface, clear of obstruction and traffic. 2 Lower the platform. 3 Turn the key switch to the off position and remove the key to secure from unauthorized use. 4 Chock the wheels. 5 Charge the batteries. 16 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Legend 12 13 14 4 15 16 17 18 11 10 9 8 16 7 6 3 4 19 2 5 4 3 2 1 23 22 21 20 1 Pothole guard 2 Non-steer tire 3 Forklift pocket 4 Transport tie-down 5 Emergency lowering valve 6 Battery charger display 7 Covers 8 Ground controls 9 Hydraulic oil level indicator 10 Power to platform/battery charger connection for optional inverter 11 Mast 12 Bike rack (if equipped) 13 Brake release pump knob (under covers) 14 Platform controls 15 Work tray 16 Dual-entry gate 17 Lanyard anchorage point 18 Parcel tray (QS-12 and QS-15) 19 Steer tire 20 GFCI outlet 21 Battery compartment cover 22 Battery cover latch 23 Manual storage container Part No. 133494 QS-12W QS-15W QS-20W 17
First Edition Second Printing Controls 2 1 00009.9 3 4 STOP 5 Ground Control Panel 1 Key switch for platform/off/ground selection Turn the key switch to the platform position and the platform controls will operate. Turn the key switch to the off position and the machine will be off. Turn the key switch to the base position and the ground controls will operate. 2 7 amp breaker for electric circuits 3 Hour meter Indicates the number of hours the machine has been put into use. 4 Platform up/down toggle switch Move the switch up and the platform will raise. Move the switch down and the platform will lower. 5 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Emergency Stop button to the on position to operate the machine. 18 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Controls Platform Control Panel 1 Thumb rocker switch for steer functions 2 Drive speed button 3 Drive function select button 4 Red Emergency Stop button 5 LED diagnostic readout / Battery charge indicator 6 Lift function select button 7 Horn button 8 Proportional control handle and function enable switch for lift and drive functions Part No. 133494 QS-12W QS-15W QS-20W 19
First Edition Second Printing Controls Platform Control Panel 1 Thumb rocker switch for steer functions Press the thumb rocker switch in either direction to activate the steer function. 2 Drive speed button Press this button to activate slow drive function. The indicator light will be on when slow drive is selected. 3 Drive function select button Press this button to activate the drive function. 4 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Emergency Stop button to the on position to operate the machine. 5 LED Diagnostic read out, battery charge indicator. 6 Lift function select button Press this button to activate the lift function. 7 Horn Button Push the horn button and the horn will sound. Release the horn button and the horn will stop. 8 Proportional control handle and function enable switch for lift and drive functions Lift function: Press and hold the function enable switch to enable the lift function on the platform control handle. Move the control handle in the direction indicated by the blue arrow and the platform will raise. Move the control handle in the direction indicated by the yellow arrow and the platform will lower. The descent alarm should sound while the platform is lowering. Drive function: Press and hold the function enable switch to enable the drive function on the platform control handle. Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will move in the direction that the blue arrow points. Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points. 20 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. Know and understand the pre-operation inspection before going on to the next section. 3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required. Only routine maintenance items specified in this manual may be performed by the operator. Refer to the list on the next page and check each of the items. If damage or any unauthorized variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. After repairs are completed, the operator must perform a pre-operation inspection again before going on to the function tests. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. Part No. 133494 QS-12W QS-15W QS-20W 21
First Edition Second Printing Inspections Pre-operation Inspection Be sure that the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. Be sure that all decals are legible and in place. See Inspections section. Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section. Check for battery fluid leaks and proper fluid level. Add distilled water if needed. See Maintenance section. Check the following components or areas for damage, improperly installed or missing parts and unauthorized modifications: Electrical components, wiring and electrical cables Hydraulic power unit, tank, hoses, fittings, cylinders and manifolds Battery pack and connections Drive motors Tires and wheels Ground strap Limit switches, alarms and horn Alarms and beacons (if equipped) Nuts, bolts and other fasteners Platform entry mid-rail bar, chain or gate Sequencing cables and pulleys Pothole guards Work trays and bike racks (if equipped) Brake release components Battery cover Mast columns and counterweight Platform control joystick Check the entire machine for: Cracks in welds or structural components Dents or damage to the machine Excessive rust, corrosion or oxidation Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened. Note: If the platform must be raised to inspect the machine, make sure the battery cover is in place. See Operating Instructions section. 22 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. Know and understand the function tests before going on to the next section. 4 Inspect the workplace. 5 Only use the machine as it was intended. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service. 1 Select a test area that is firm, level and free of obstruction. 2 Be sure the batteries are connected. At the Ground Controls 3 Pull out the platform and ground red Emergency Stop buttons to the on position. 4 Turn the key switch to ground control. 5 Observe the diagnostic LED readout on the platform controls. Result: The LED should look like the picture at right. Test Emergency Stop 6 Push in the ground red Emergency Stop button to the off position. Result: No functions should operate. 7 Pull out the red Emergency Stop button to the on position. Part No. 133494 QS-12W QS-15W QS-20W 23
First Edition Second Printing Inspections Test the Up/Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm. The horn is a constant tone. The descent alarm sounds at 60 beeps per minute. The alarm that goes off when the pothole guards have not deployed sounds at 300 beeps per minute. The alarm that goes off when the machine is not level sounds at 600 beeps per minute. An optional automotive-style horn is also available. 8 Activate the up function. Result: The platform should raise. 9 Activate the down function. Result: The platform should lower. The descent alarm should sound while the platform is lowering. Test Emergency Lowering 10 Activate the up function and raise the platform approximately 2 ft / 60 cm. 11 Pull the Emergency lowering knob located at the base of the machine below the mast. Result: The platform should lower. The descent alarm will not sound. 12 Turn the key switch to platform control. At the Platform Controls Test Emergency Stop 13 Push in the platform red Emergency Stop button to the off position. Result: No functions should operate. Test the Horn 14 Pull out the red Emergency Stop button to the on position. 15 Push the horn button. Result: The horn should sound. Test the Function Enable Switch 16 Do not hold the function enable switch on the control handle. 17 Slowly move the control handle in the direction indicated by the blue arrow, then in the direction indicated by the yellow arrow. Result: No functions should operate. Test the Up/Down Functions 18 Press the lift function select button. 19 Press and hold the function enable switch on the control handle. 20 Slowly move the control handle in the direction indicated by the blue arrow. Result: The platform should raise. The pothole guards should deploy 24 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Inspections 21 Release the control handle. Result: The platform should stop raising. 22 Press and hold the function enable switch. Slowly move the control handle in the direction indicated by the yellow arrow. Result: The platform should lower. The descent alarm should sound while the platform is lowering. Test the Steering Note: When performing the steer and drive function tests, stand in the platform facing the steer end of the machine. 23 Press the drive function select switch. 24 Press and hold the function enable switch on the control handle. 25 Depress the thumb rocker switch on top of the control handle in the direction indicated by the blue triangle on the control panel. Result: The steer wheels should turn in the direction that the blue triangle points on the control panel. 26 Depress the thumb rocker switch in the direction indicated by the yellow triangle on the control panel. Result: The steer wheels should turn in the direction that the yellow triangle points on the control panel. Test Drive and Braking 27 Press and hold the function enable switch. 28 Slowly move the control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move, then return the handle to the center position. Result: The machine should move in the direction that the blue arrow points on the control panel, then come to an abrupt stop. 29 Slowly move the control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move, then return the handle to the center position. Result: The machine should move in the direction that the yellow arrow points on the control panel, then come to an abrupt stop. Note: The brakes must be able to hold the machine on any slope it is able to climb. Test the Tilt Sensor Operation 30 Locate the tilt sensor located above the ground controls panel behind the ground controls cover. 31 Press down one side of the tilt sensor and place the tilt sensor test tool under one of the posts. Result: The alarm, located in the platform, should sound after 1 second. Part No. 133494 QS-12W QS-15W QS-20W 25
First Edition Second Printing Inspections 32 Test all ground and platform control functions. Result: Before the platform is raised approximately 1 ft / 30 cm, the lift function should stop, an alarm should sound and the LED readout should display LL. 33 Remove the tilt sensor test tool. 34 Turn the key switch to platform control. Test Limited Drive Speed 35 Press the lift function select button. 36 Press and hold the function enable switch on the control handle. Raise the platform approximately 2 ft / 60 cm from the ground. 37 Press the drive function select button. 38 Press and hold the function enable switch on the control handle. Slowly move the control handle to the full drive position. Result: The maximum achievable drive speed with the platform raised should not exceed 0.7 ft / 20 cm per second. If the drive speed with the platform raised exceeds 0.7 ft / 20 cm per second, immediately tag and remove the machine from service. Test the Pothole Guards Note: The pothole guards should automatically deploy when the platform is raised. The pothole guards activate another limit switch which allows the machine to continue to function. If the pothole guards do not deploy, an alarm sounds and the machine will not drive. 39 Raise the platform. Result: When the platform is raised 4 ft / 1.2 m from the ground, the pothole guards should deploy. 40 Press on the pothole guards on one side, and then the other. Result: The pothole guards should not move. 41 Lower the platform. Result: The pothole guards should return to the stowed position. 42 Place a 2x4 or similar piece of wood under a pothole guard. Raise the platform. Result: Before the platform is raised 7 ft / 2.1 m from the ground, an alarm should sound and the drive function should not work. 43 Lower the platform and remove the 2x4. 26 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: drop-offs or holes Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the workplace. Know and understand the workplace inspection before going on to the next section. 5 Only use the machine as it was intended. bumps, floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace. It is the operator's responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine. Part No. 133494 QS-12W QS-15W QS-20W 27
First Edition Second Printing Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity 28174 Label - Power to Platform, 230V 2 28175 Warning - Compartment Access 1 28235 Label - Power to Platform, 115V 2 28373 Label - Forklift Pocket 2 31071 Warning - Failure to Read Manual 1 31508 Danger - Electrocution Hazard, Plugs 1 31788 Danger - Battery/Charger Safety 1 38122 Label - Manual Storage Container 1 40434 Label - Lanyard Anchorage 1 43089 Instructions - Operating Instructions, Ground 1 43658 Label - Power to Charger, 230V 1 44736 Danger - Tip-over Hazard, Tilt Alarm 1 44980 Label - Power to Charger, 115V 1 52475 Label - Transport Tie-down 3 52865 Warning - Annual Service Inspection 1 65052 Label - ECM Fault Codes 1 72086 Label - Lifting Eye 1 72159 Danger - Tip-over Hazard, Batteries 1 72171 Instructions - Max Side Force, 100 lbs / 445 N, ANSI 1 72188 Label - Directional Arrows 2 72832 Danger - Do Not Alter Limit Switch 1 72970 Instructions - Battery Charger Operation 1 82366 Label - Chevron Rando 1 82863 Danger - Parcel Tray Capacity, 150 lbs / 68 kg, QS-12W, QS-15W 1 82864 Danger - Max Capacity, 45 lbs / 20 kg, Bike Racks 1 82975 Danger - Collision Hazard 1 Part No. Description Quantity 97712 Instructions - Brake Release Safety and Operation 1 97772 Platform Control Panel 1 97829 Instructions - Max Capacity, 500 lbs / 227 kg, QS-12W & QS-15W 1 97830 Instructions - Max Capacity, 350 lbs / 159 kg, QS-20W 1 97831 Instructions - Operating Instructions, Platform 1 109519 Danger - Max Capacity, 150 lbs / 68 kg, Work Tray 2 114325 Instructions - Battery Connection Diagram 1 114469 Ground Control Panel 1 133013 Danger - Electrocution Hazard 1 133014 Danger - General Safety Rules 1 133092 Danger - Crushing Hazard, Use Safety Chock 1 133144 Label - Transport Diagram 2 133199 Label - Emergency Lowering 1 133429 Label - ECM Fault Codes, Obstruction Sensing System 1 133450 Instructions - Adjustable Work Tray 1 133451 Danger - Max Capacity, 45 lbs / 20 kg, Bike Racks 2 133505 Label - Wheel Load 4 133506 Cosmetic - Genie QuickStock 1 133510 Cosmetic - Genie QS-12W 2 133511 Cosmetic - Genie QS-15W 2 133512 Cosmetic - Genie QS-20W 2 133515 Label - Tire Specifications 4 28 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Inspections 31071 72832 97831 44736 109519 82864 97829 or 97830 28175 133013 82863 72188 Shading indicates decal is hidden from view, i.e., under covers. 133450 109519 40434 28235 or 28174 82366 82975 31788 97712 28373 133515 72171 38122 133506 133505 133510 or 133511 or 133512 72086 Serial Label 28235 or 28174 114469 43089 52865 72159 52475 114325 133505 133515 133092 133144 65052 97772 133014 72970 44980 or 43658 31508 28373 133515 52475 133199 133144 52475 133451 133515 133505 133510 or 133511 or 133512 133505 Part No. 133494 QS-12W QS-15W QS-20W 29
First Edition Second Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity 28174 Label - Power to Platform, 230V 2 28235 Label - Power to Platform, 115V 2 40434 Label - Lanyard Anchorage 1 43658 Label - Power to Charger, 230V 1 44980 Label - Power to Charger, 115V 1 52475 Label - Transport Tie-down 3 72086 Label - Lifting Eye 1 72188 Label - Directional Arrows 2 82473 Label - Compartment Access 1 82481 Label - Battery Safety 1 82487 Label - Read the Manual 2 82495 Label - Brake Release Safety and Operation 1 82614 Label - Collision Hazard 1 82666 Label - Forklift Pocket 2 82836 Label - Emergency Lowering 1 82966 Label - Max Side Force, 445 N, ANSI 1 97772 Platform Control Panel 1 97834 Label - Max Capacity, 227 kg, QS-12, QS-15 1 97835 Label - Max Capacity, 159 kg, QS-20 1 97871 Label - Max Capacity, Bike Rack, 20 kg, QS-12, QS-15 1 97872 Label - Max Capacity, Bike Rack, 20 kg, QS-20 1 97898 Label - Max Capacity, Parcel Tray, 68 kg, QS-12, QS-15 1 Part No. Description Quantity 97899 Label - Safety Chock 1 114334 Label - Electrocution Hazard, Plug 1 114338 Label - Tip-over Hazard, Tilt Alarm 1 114469 Ground Control Panel 1 133015 Label - Electrocution Hazard 1 133144 Label - Transport Diagram 2 133146 Label - Tip-over Hazard, Batteries 1 133147 Label - Tip-over Hazard, Limit Switch 1 133498 Label, Tip-over Hazard, Bike Rack 2 133505 Label - Wheel Load 4 133506 Cosmetic - Genie QuickStock 1 133510 Cosmetic - Genie QS-12W 2 133511 Cosmetic - Genie QS-15W 2 133512 Cosmetic - Genie QS-20W 2 133513 Label, Max Capacity, Tray, 68 kg, QS-12, QS-15 1 133514 Label, Max Capacity, Tray, 68 kg, QS-20 1 30 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Inspections 97898 133147 97871 or 97872 82487 97834 or 97835 82966 114338 72188 82473 133015 133513 or 133514 40434 28235 or 28174 97815 82614 82481 82495 133506 82666 133505 133510 or 133511 or 133512 72086 Serial Label 28235 or 28174 114469 133146 52475 133505 97899 133144 97772 82487 44980 or 43658 114334 82666 52475 82836 133144 52475 133498 133505 133510 or 133511 or 133512 133505 Part No. 133494 QS-12W QS-15W QS-20W 31
First Edition Second Printing Operating Instructions Fundamentals Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended. The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Using the machine for anything other than lifting personnel, along with their tools and materials, to an aerial work site is unsafe and dangerous. Only trained and authorized personnel should be permitted to operate a machine. If more than one operator is expected to use a machine at different times in the same work shift, they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator's, safety and responsibilities manuals. That means every new operator should perform a pre-operation inspection, function tests, and a workplace inspection before using the machine. 32 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Operating Instructions Emergency Stop Push in the red Emergency Stop button to the off position at the ground or platform controls to stop all functions. Repair any function that operates when either red Emergency Stop button is pushed in. Emergency Lowering 1 Pull the Emergency lowering knob. Operation From Ground 1 Turn the key switch to ground control. 2 Pull out both ground and platform red Emergency Stop buttons to the on position. 3 Be sure the battery pack is connected before operating the machine. To Position Platform 1 Move the up/down toggle switch according to the markings on the control panel. Drive and steer functions are not available from the ground controls. Operation From Platform 1 Turn the key switch to platform control. 2 Pull out the ground and platform red Emergency Stop buttons to the on position. 3 Be sure the battery pack is connected before operating the machine. To Position Platform 1 Press the lift function select button. 2 Press and hold the function enable switch on the control handle. 3 Move the control handle according to the markings on the control panel. To Steer 1 Press the drive function select button. 2 Press and hold the function enable switch on the control handle. 3 Turn the steer wheels with the thumb rocker switch located on the top of the control handle. To Drive 1 Press the drive function select button. 2 Press and hold the function enable switch on the control handle. 3 Increase speed: Slowly move the control handle off center. Decrease speed: Slowly move the control handle toward center. Stop: Return the control handle to center or release the function enable switch. Use the color-coded direction arrows on the platform controls and on the platform to identify the direction the machine will travel. Part No. 133494 QS-12W QS-15W QS-20W 33
First Edition Second Printing Operating Instructions Machine travel speed is restricted when the platform is raised. Battery condition will affect machine performance. Machine drive speed and function speed will drop when the battery level indicator is flashing. To Reduce Drive Speed The drive controls can operate in two different drive speed modes. When the drive speed button light is on, slow drive speed mode is active. When the button light is off, fast drive speed mode is active. Press the drive speed button to select the desired drive speed. Driving on a slope Determine the slope and side slope ratings for the machine and determine the slope grade. Maximum slope rating, stowed 30% (17 ) Maximum side slope rating, stowed 30% (17 ) To determine the slope grade: Measure the slope with a digital inclinometer OR use the following procedure. You will need: carpenter s level straight piece of wood, at least 3 feet / 1 m long tape measure Lay the piece of wood on the slope. At the downhill end, lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level. While holding the piece of wood level, measure the distance from the bottom of the piece of wood to the ground. Divide the tape measure distance (rise) by the length of the piece of wood (run) and multiply by 100. Example: run Note: Slope rating is subject to ground conditions and adequate traction. Press the drive speed button to the fast drive speed mode. rise Run = 12 ft (144 in) / 3.6 m Rise = 12 in / 0.3 m 12 in 144 in = 0.083 x 100 = 8.3% 0.3 m 3.6 m = 0.083 x 100 = 8.3% If the slope exceeds the maximum slope or side slope rating, the machine must be winched or transported up or down the slope. See Transport and Lifting section. 34 QS-12W QS-15W QS-20W Part No. 133494
First Edition Second Printing Operating Instructions Error indicator readout ECM Fault Codes Code Condition -- Condition Normal 01 Internal ECM Error If the LED diagnostic readout displays an error code, such as LL, push in and pull out the red Emergency Stop button to reset the system. 02 ECM/Platform Communication Error 03 Undefined Platform Dip Switch Setting 12 Chassis Up/Down Toggle Closed At Startup 18 Pothole Guard Failure 42 Platform Left Turn Switch Fault 43 Platform Right Turn Switch Fault 46 Platform Drive Enable Switch Fault 47 Platform Joystick Fault 52 Forward Coil Fault 53 Reverse Coil Fault To Raise and Lower Work Tray To raise the work tray: 1 Grasp a side rail carefully with one hand. 2 Grasp the hole located in the center of work tray with other hand. 3 Raise the work tray until it is level with the work tray mount. 4 Lower the work tray until the snap pin engages. Note: The snap pin must be properly engaged for proper work tray use. To lower the work tray: 5 Pull the snap pin while vertically raising tray to clear the work tray mount. 6 Lower the work tray to the stowed position. b a c 54 Up Coil Fault 55 Down Coil Fault 56 Right Coil Fault 57 Left Coil Fault 58 Brake Coil Fault 59 Parallel/Series Coil Fault 68 Low Battery Voltage LL Off-Level OL Overload Cutout Option a b c d work tray handle snap pin work tray mount d For more information, please consult the appropriate Genie Service Manual. Part No. 133494 QS-12W QS-15W QS-20W 35